Apparatus for Securing a Solar Panel Rail Guide to a Support Bracket

ABSTRACT

In various representative aspects, an assembly for securing a support bracket to rail guide used for mounting and installing solar panels is provided. More specifically, the assembly provides a novel and improved nut with a serrated surface in combination with a t-bolt with a serrated surface that is capable of penetrating the respective oxidation surface layers of the bracket and the rail guide when installed. When installed, provides a mechanism for using the bracket to connect the rail guide to a flashing that is typically installed on a roof. By employing the apparatus at various locations along the roof in a linear fashion, the rail support structure can be properly installed so that an array of solar panel modules to be installed.

BACKGROUND OF INVENTION

Field of the Invention

The present invention relates generally to an apparatus for securing abracket to a solar panel rail support structure, while providing anelectrical bonding path between the bracket and the support structure.More specifically, the apparatus provides a novel and improved nut witha serrated surface in combination with a bolt with an enlarged end liket-bolt with a serrated surface that is capable of penetrating therespective oxidation surface layers of the bracket and the rail guide.The combination is typically used to secure a bracket, and as describedherein by way of example, an L-shaped bracket. By employing theapparatus at various locations along the roof in a linear fashion, therail support structure can be properly installed so that an array ofsolar panel modules to be installed.

Description of the Related Art

Any discussion of the prior art in the specification should in no way beconsidered as an admission that the prior art is widely known or formspart of common general knowledge in the field.

The installation of solar panel arrays on residential roofs can bearduous and time-consuming. Depending on the array design, thecomponents required to install the array can make the installationprocess even more difficult. Many of the assembly components requirespecial tools or are generally difficult to install because they areutilized after the solar panels modules are arranged or positioned ontheir support elements. This is particularly true when the elements mustbe installed on a roof that links to a rail guide for supporting thesolar panel array.

In a typical support rail guide system, solar panel modules are arrangedacross the top of several rail guides. This typically occurs, forexample, by using mounting clamps that join two solar panel modulesalong the top of the rail guide. The rail guides in turn are supportedby flashings that are connected by using a support bracket between theflashing and the rail guide. A typical support bracket is in the shapeof an “L”, but can be any suitable shape that serves to connect theflashing to the rail guide.

When connecting the support bracket between the flashing and the railguide, a nut and bolt combination is typically used. The presentinvention employs a combination bolt with an enlarged end and nut thatnot only secures the bracket to the rail guide, but also provides anelectrical bonding path between the rail guide and the bracket.

Existing solutions are typically limited by their inability to easilyand precisely secure the bracket to the rail guide while using extrabonding washers or bonding components, while also creating an electricalbonding path. One example of this is shown in U.S. Pat. No. 7,073,995issued to Herb. The '995 patent discloses a nut and bolt combinationthat has an elongated member 4 that can fit in a mounting rail 3. Theelongated member has a recessed portion 18.1 and 18.2 that is adapted toreceive holding projections 17.1 and 17.2 respectively when screw 8 istightened into the elongated member. The screw can also haveindentations 38 (FIG. 4b ), but these indentations are provided solelyto engage servo components 33 to form a locking mechanism. The '995patent does not teach or suggest a combination nut and bolt wherein thebolt has an elongated member such that the elongated member and thebottom surface of the nut include raised portions for penetrating thesurface layer of metal objects to create an electrical bonding pathbetween them. The '995 patent also does not disclose that the elongatedmember of the bolt can be inserted lengthwise in a slot of a solar panelrail guide, engage the rail guide so that raised portions on theelongated member penetrate a surface treatment layer of the rail guidewhen the nut is tightened, and have the raised portions of the nutengage a bracket that supports the rail guide and penetrate the surfacetreatment layer of the bracket as well, which creates an electricalbonding path between these objects. The present invention overcomes thelimitations of the '995 patent.

The present invention overcomes these limitations and offers a solutionthat provides a nut and bolt combination that secures a support bracketto a solar panel rail guide slot that creates an electrical bonding pathbetween the rail guide and the bracket that is easy to install, use, andmanufacture.

SUMMARY OF THE INVENTION

The invention is summarized below only for purposes of introducingembodiments of the invention. The ultimate scope of the invention is tobe limited only to the claims that follow the specification.

It is an object of this invention to provide an assembly for securing abracket to a solar panel rail guide structure.

It is a further object of this invention that the assembly comprise abolt that comprises an elongated member on an end of the bolt.

It is a further object of this invention that the elongated membercomprises a raised portion capable of penetrating a surface layer of asolar panel rail guide.

It is a further object of this invention that a nut engages an endopposite the elongated member on the bolt.

It is a further object of this invention that the nut comprises a raisedportion capable of penetrating a surface layer of a bracket thatsupports the solar panel rail guide.

It is a further object of this invention that the elongated member becapable of insertion lengthwise along the length of the solar panel railguide slot such that when the elongated member is rotated when turned bythe nut, the elongated member will engage the slot of the rail guide andenable the nut to turn until the support bracket is secured between thenut and the solar panel rail guide.

A person with ordinary skill in the relevant art would know that anyshape or size of the elements described below may be adopted. Anycombinations of suitable number, shape, and size of the elementsdescribed below may be used. Also, any materials suitable to achieve theobject of the current invention may be chosen as well.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived byreferring to the detailed description and claims when considered inconnection with the following illustrative figures. In the followingfigures, like reference numbers refer to similar elements and stepsthroughout the figures.

FIG. 1 illustrates a perspective view of an exemplary nut.

FIG. 2 illustrates a side view of the nut shown in FIG. 1.

FIG. 3 illustrates a perspective view of the nut shown in FIG. 1 coupledto a bolt with an elongated member.

FIG. 4 illustrates a reverse perspective view of FIG. 3.

FIG. 5 illustrates a perspective view of a fully assembled exemplarybracket to an exemplary rail guide using the nut and bolt combinationshown in FIGS. 3 and 4.

FIG. 6 illustrates a cross-sectional view of FIG. 5 showing the nut andbolt securing the bracket to the solar panel rail guide.

FIG. 7 illustrates a close up view of the circled area 7 in FIG. 6showing the raised portions on the nut and bolt penetrating the surfacesof the bracket and solar panel rail guide respectively.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, and for the purposes of explanation,numerous specific details are provided to thoroughly understand thevarious aspects of the invention. It will be understood, however, bythose skilled in the relevant arts, that the present invention may bepracticed without these specific details. In other instances, knownstructures and devices are shown or discussed more generally in order toavoid obscuring the invention. In many cases, a description of theoperation is sufficient to enable one to implement the various forms ofthe invention, particularly when the operation is to be implemented insoftware. It should be noted that there are many different andalternative configurations, devices and technologies to which thedisclosed embodiments may be applied. The full scope of the invention isnot limited to the example(s) that are described below.

FIGS. 1 and 2 show perspective and side views respectively of anexemplary embodiment of a nut 100. The nut 100 is typically made ofmetal or an electrically conducting material. The nut 100 includes head110. The head 110 shown in this embodiment includes two parts—a largehexagonal portion 110, and a smaller hexagonal portion 115 that is tothe rear of the larger portion 110. These hexagonal portions 110 and 115provide a gripping structure for human hands as well as two sizes ofsocket wrenches or pliers to enable the nut 100 to be turned fortightening or loosening. It is understood by those skilled in the artthat the shape of the gripping structure can be hexagonal, or of anysuitable shape that provides a secure connection. The nut 100 alsoincludes a female threaded portion 130 for receiving the bolt 150 asshown in FIG. 3. An annular flange 120 is provided on the lower end ofthe nut 100. The flange 120 is not limited to the annular shape and canalso be of any suitable shape. It is also understood that the flange 120can be the same or greater diameter of the large hexagonal portion 110.The annular flange 120 also includes serrated portions 140 on the bottomsurface of the flange 120. The serrated portions 140 can number as fewas one, or as many as can be reasonably fit along the surface of theflange 120. The serrated portions 140 should also be as sharp asnecessary for them to be able to penetrate a surface layer of a supportbracket 300 as shown in FIG. 5 to form a conducting bond between thesupport bracket 300 and the flange 120.

FIGS. 3 and 4 illustrate perspective views of an exemplary combinationnut 100 and bolt 155. The bolt 155 is typically what is described as a“t-bolt” and includes a threaded shank 150 that extends outward from oneside of an enlarged end 160. The shank 150 and the enlarged end 160 arecoupled either in two elements or as a single part. The enlarged end 160is typically in the shape of a rectangular prism and, along with theshank 150, is electrically conductive. Generally, the size of theenlarged end 160 should allow it to be inserted lengthwise into a slot230 on the rail guide 200 as will be discussed below in FIGS. 5-7, yetcapable of being rotated into a locked position as shown in FIGS. 6-7 sothat the enlarged end 160 is substantially perpendicular to the openingof the slot 230. As shown in FIGS. 3-4, the shank 150 is engaged withthe nut 100 by screwing it into the female threaded portion 130. On thetop surface of the enlarged end 160 where the shank 150 extends outward,a plurality of raised portions 170 are included. These raised portions170 are generally sharp enough so that they can penetrate the surfacelayer of an electrically conducting material and create an electricalconducting path between the raised portions 170 and that material. Theraised portions 170 can number as few as one. But generally, a greaternumber of raised portions 170 that are present on the surface create abetter electrical conducting path.

FIG. 5 illustrates an exemplary installation of the assembly. As shown,the rail guide 200 is coupled to the support bracket 300 by way of thenut 100 and bolt 155 combination. The top rail 220 on the rail guide 200is generally used to support several solar panel modules. A clamp (notshown) fits within the slot of 220 and connects and electrically bondsthe modules. Generally, the rail guide 200 extends for a long distancefrom one end of a roof to another and is supported by multiple supportbrackets 300 separated by distinct distances apart.

Although the enlarged end 160 can be inserted at the slot end 210, thisis not desirable when the rail guide 200 extends for several feet acrossa roof. For this reason, inserting each enlarged end 160 lengthwise atdiscrete distances along the slot 230 overcomes this limitation. Onceinserted, the nut 110 is then engaged with the threaded shank portion150 and is typically rotated by hand without the use of extra tools tosecure it to the shank 150. As the nut 110 is rotated, the enlarged end160 rotates inside of the slot 230 and stops rotating when the edges ofthe enlarged end 160 are perpendicular to, and in contact with theinside surface of the slot 230.

Once the enlarged end 160 is engaged with the inside surface of the slot230, the support bracket 300 is then inserted between the nut and theface 240 of the rail guide 200 along the aperture 330 and moved intoposition until a desired height is achieved. The nut 110 is then rotateduntil the serrations 140 begin to contact the surface of the bracket300. As the nut 110 is further rotated and tightened, the serrations 140will penetrate the surface layer of the bracket 300 and the raisedportions 170 on the enlarged end 160 begin to penetrate the surfacelayer of the slot 230 within the rail guide 200 as shown in more detailin FIGS. 6-7. This in turn creates an electrical bonding path betweenthe rail guide 200 and the bracket 300. Gripping features 320 can alsoprovide greater stability for the bracket 300 to further prevent it fromsliding up or down when the face of the rail guide 200 once the bracket300 is secured. When the bracket 300 is electrically coupled to aflashing (not shown) through opening 310, and the rail guide 200 iselectrically coupled to solar panel modules along its top rail 220, thesolar panel array is fully electrically connected.

What is claimed is:
 1. A clamping apparatus for facilitating thecompletion of an electrical circuit between a solar panel rail guide anda support bracket comprising: a. a bolt comprising; i. an enlarged endcomprising at least one raised portion on a top surface of the enlargedend for penetrating a surface treatment layer of the solar panel railguide; ii. a shank having a first end and a second end wherein the firstend is coupled to the top surface of the enlarged so that the shank isperpendicular to the enlarged end; b. a nut comprising at least oneserration on a bottom side of the nut for penetrating a surfacetreatment layer of the support bracket and the nut being coupled to thesecond end of the shank through an opening on the bottom side; c. andthe enlarged end is insertable in a first orientation along a length ofthe solar panel rail guide and rotatable to a second orientation suchthat the enlarged end engages the rail support guide.
 2. The clampingapparatus of claim 1 wherein the shank is threaded.
 3. The clampingapparatus of claim 2 where in the opening on the bottom side of the nutis threaded and adapted to engage the threaded shank by rotating the nutaround the threaded shank.
 4. The clamping apparatus of claim 1 whereinthe nut further comprises a gripping structure on a top side of the nut.5. The clamping apparatus of claim 1 wherein the support bracket is asubstantially L-shaped bracket.
 6. An assembly for facilitating thecompletion of an electrical circuit between a first and second objectcomprising: a. a solar panel rail guide comprising: i. a slotcomprising: an opening along its length and; a surface treatment layer;b. a support bracket comprising: i. an aperture and; ii. a surfacetreatment layer; c. a bolt comprising; i. an enlarged end comprising atleast one raised portion on a top surface of the enlarged end forpenetrating the surface treatment layer of the slot of the solar panelrail guide; ii. a shank having a first end and a second end wherein thefirst end is coupled to the top surface of the enlarged so that theshank is perpendicular to the enlarged end; d. a nut comprising at leastone serration on a bottom side of the nut for penetrating the surfacetreatment layer of the support bracket and the nut being coupled to thesecond end of the shank through an opening on the bottom side; e. theenlarged end being insertable in a first orientation through the openingalong the length of the solar panel rail guide and rotatable to a secondorientation such that the enlarged end engages the rail support guide.7. The assembly of claim 6 wherein the shank is threaded.
 8. Theassembly of claim 7 where in the opening on the bottom side of the nutis threaded and adapted to engage the threaded shank by rotating the nutaround the threaded shank.
 9. The assembly of claim 6 wherein the nutfurther comprises a gripping structure on a top side of the nut.
 10. Amethod of installing a solar panel rail guide to a support structurecomprising the steps of: a. Inserting an enlarged end of a bolt into anopening of a slot along a length of a solar panel rail guide wherein thet-bolt further comprises a shank extending from the enlarged end; b.coupling a nut to an end opposite the enlarged end of the bolt; c.inserting a support bracket between the nut and the slot of the solarpanel rail guide so that the shank fits through an opening of thesupport bracket; d. rotating the nut so that the enlarged end rotates toa position substantially perpendicular to the opening of the slot andengages the slot; e. continuing to rotate the nut until at least oneserration on a bottom surface of the nut penetrates a surface oxidationlayer of the support bracket and at least one raised portion on a topsurface of the enlarged end penetrates a surface oxidation layer of theslot and creates an electrical grounding path between the solar panelrail guide and the support bracket.